Rearview mirror constructed for efficient assembly

ABSTRACT

A mirror assembly includes a housing, an angularly adjustable power pack, wires for supplying power and mirror angle control, an electrochromic mirror subassembly including a heater, and a turn signal device. The components include individual connectors that plug into a multi-prong connector on the bundle of wires, or that piggyback into each other. Optionally, the heater incorporates an internal wire with end connectors for communicating power to opposite sides of the heater, and also includes layers of light-transmitting/diffusing material for diffusing light passing from the turn signal device through the diffusing material. A printed circuit board fits into a pocket in the panel-shaped carrier, and an integral retainer releasably secures the printed circuit board. The power pack is attached to the carrier via a ring of resilient fingers, and a continuous hoop flange prevents distortion of the carrier and in turn of the glass elements in the mirror subassembly.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.11/143,233, entitled REARVIEW MIRROR CONSTRUCTED FOR EFFICIENT ASSEMBLY,which was filed on Jun. 2, 2005, which was a continuation of U.S. Pat.No. 6,963,438, entitled REARVIEW MIRROR CONSTRUCTED FOR EFFICIENTASSEMBLY, which was a continuation of U.S. Pat. No. 6,650,457, entitledREARVIEW MIRROR CONSTRUCTED FOR EFFICIENT ASSEMBLY, the entiredisclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to a rearview mirror for vehiclesconstructed for efficient and optimal assembly, including componentsshaped for efficient and low-scrap molding and manufacture, componentshaving features integrated into them to reduce the overall number ofparts, pieces, and total weight, and components arranged to facilitatemechanical assembly and physical layout as well as electricalinterconnection and repair of electrical circuits.

Modern vehicle mirrors often include numerous electrical components thatmust be powered and also controlled. For example, the electricalcomponents of one proposed high-end exterior mirror will include anelectrochromic image-darkening mirror subassembly and control circuit, aheater, a turn signal, and a powered angular adjustment mechanism. Othermirrors, such as interior mirrors, include a multitude of sensors,buttons, and readouts/displays. Routing of wires to support the variouselectrical components can be a logistic nightmare, and further, even ifrouted carefully and consistently, can take up considerable space. Also,most mirror designs provide electrical connectors so that the mirror canbe electrically coupled to a vehicle's electrical system on or about thesame time as the mirror is mechanically attached to the vehicle. It isdesirable to reduce the amount of time that it takes to arrange wiringand connectors on the mirror, and to reduce the amount of time it takesto manipulate connectors and then electrically connect the multipleelectrical components of a mirror to each other and to the vehicleelectrical system.

Another problem caused by multiple components in a mirror is that themirror becomes thicker in order to make room for the wiring andconnectors and also heavier due to the connectors, wires, and relatedsupport structure. Modern vehicles place a high emphasis on low weightand small size, especially for non-visible components. Weight, even insmall amounts, is an issue in electrochromic mirror subassembliesbecause these mirrors use a pair of glass elements with anelectrochromic layer therebetween. They also require the supportingcircuitry and hardware. Glass has a relatively high specific gravity,and since electrochromic mirror subassemblies require a pair of glasselements, these mirror subassemblies tend to be heavier thannon-electrochromic mirrors. In opposition to the issue of reducingweight by reducing glass thickness, glass elements must be thick enoughto prevent distortion of reflected images, since this is related to avehicle driver's ability to see around and safely drive a vehicle. Mostexisting mirror glass elements in EC mirror subassemblies are about2.2-mm in thickness or greater. Vehicle manufacturers have hesitatedgoing below this thickness because the glass elements will bend tooeasily, resulting in distortion of the reflected images. Further, a wayis needed to support the glass elements in a non-stressed manner,especially during wide temperature fluctuations and other stress-risingincidents that occur in the environment of a vehicle in service.

Further, it is preferable that various functions and features be wellintegrated into the components of a mirror assembly to minimize thetotal number of parts and pieces. At the same time, it is oftendesirable to maintain repairability so that expensive components do nothave to be scrapped and thrown away when a defect occurs in othercomponents during the last few steps of a manufacturing process for themirror. There is tension between the concept of “integrated features andcomponents” and “repairability” when trying to optimize a mirror formanufacture. For example, “well integrated features and components” tendto require less electrical connectors and less manual assembly (i.e.since the components are integrated into the mirror), and initially costless as a result. However, sometimes it is desirable to add electricalconnectors so that defective components can be removed and replaced andso that scrap can be better controlled and/or so that assemblyefficiency can be improved.

Recently, some manufacturers are considering placing a turn signal in anexterior vehicle mirror. This can cause several difficulties andcomplications in a mirror. For example, the light-generating turn signaldevice adds weight and takes up space, such that the resulting assemblyis potentially heavier and larger than mirror assemblies not having thisfeature. Further, the turn signal device requires additional wiringwithin the mirror assembly, which can cause assembly concerns related toelectrical connections and positioning of connectors, as discussedabove. Further, a defective turn signal device non-removably attached toan electrochromic mirror subassembly can result in scrapping out andthrowing away a “good” electrochromic mirror subassembly, which is arelatively expensive portion of the overall assembly at that same pointin time. At the same time, it is desirable to securely attach the turnsignal device to the mirror assembly so that it does not come loosewhile in service. One reason is because, if the turn signal device cameloose in an exterior mirror assembly, dirt and light-blocking matterwould soon cover the turn signal device, rendering it ineffective. Also,it could rattle and cause other problems.

It is desirable to improve assembly of the electrochromic mirrorsubassembly to the angular adjustment mechanism (often called a “powerpack”). Historically, the power pack includes an electrically-poweredangularly-adjustable mount, and the electrochromic mirror subassemblyincludes a carrier with a connector having resilient fingers shaped tosnappingly engage the adjustable mount. However, as the resilientfingers are flexed to engage and then do engage the adjustable mount,the glass-supporting area around the fingers is distorted. This can be aproblem since, if the glass is less than about 2.2-mm thick and thecarrier thickness is also minimized for reduced weight, the distortionof the glass-supporting area can read through to the glass, causingnoticeable and objectionable distortions in the reflected images.Distortion of the glass-supporting area can be reduced by making thefingers flimsier and not as stiff, however this would result in areduced retention force and less reliable connection of theelectrochromic mirror subassembly to the power pack. Distortion of theglass-supporting area can also potentially be reduced by placement ofperpendicular reinforcement webs on the carrier. This, however, addsweight and takes up considerable space if the reinforcement webs aremade large enough to do an adequate job. Further, testing has shown thatit is not a solution to this problem to merely add a few randomreinforcement webs, since very minor bending in a directionperpendicular to the glass elements of the mirror subassembly in anylocalized area can result in objectionable glass distortions, especiallywith glass elements at or under 1.6-mm thickness. It is important thatthe insertion force for attaching the carrier to the adjustable mountnot be too high of force, that it not be an inconsistent force, and yetthat the retention force not permit looseness, sloppiness, poor andinconsistent retention forces.

In addition to the above, it is desirable to design a carrier for the ECmirror subassembly that can be molded with molding dies that are notcomplicated and that do not include a plurality of movable pulls andslides that are difficult to maintain. Pulls and slides in molding diesare well known, and are often used to mold parts. However, pulls andslides are expensive to build into a die and to maintain, and can resultin increased scrap. Further, it is desirable to provide a carrier thatprovides ease and reliability of assembly, with few parts and pieces,especially having few small parts and pieces such as screws and separatefasteners that must be manipulated and/or connected without stripping.

Accordingly, a mirror assembly is desired solving the aforementionedproblems and having the aforementioned advantages.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the present invention, a mirror assembly includes anelectrochromic mirror including a first connector operably connected tothe electrochromic mirror, and an electrically-operated second componentassociated with the electrochromic mirror that includes a secondconnector operably connected to the electrically-operated secondcomponent. A primary wire bundle extends from and is configured tocommunicate power to the electrochromic mirror and to theelectrically-operated second component, the primary wire bundleincluding a main connector. The first connector engages and iselectrically connected to the main connector, and the second connectorengages and is electrically connected to one of the main connector andthe first connector. By this arrangement, the primary wire bundle isconfigured to communicate power to the electrochromic mirror and to thesecond component in a manner minimizing the number of electricalconnections and connectors necessary during assembly to a mirrorhousing.

In another aspect of the present invention, a rearview mirror assemblyfor a vehicle includes a housing, and a mirror subassembly positioned inthe housing and including a panel-shaped carrier. First and secondelectrically-operated components are associated with the mirrorsubassembly and include first and second connectors, respectively. Aprimary wire bundle extends from and is configured to communicate powerto the first and second components, the primary wire bundle including amain connector. The first and second connectors engage and areelectrically directly connected to the main connector. By thisarrangement, the primary wire bundle and the first and second connectorsare configured to communicate power to the first and second componentsin a manner minimizing the number of electrical connections necessaryduring assembly to a vehicle.

In another aspect of the present invention, a rearview mirror assemblyfor a vehicle includes a mirror subassembly, and a heater positionedrelative to the mirror subassembly for heating the mirror subassembly.The heater includes a first connector on one side of the heater and asecond connector on another side of the heater with an electricalconductor extending through and across the heater and connecting thefirst and second connectors. By this arrangement, electrical energy canbe communicated by the electrical conductor to different sides of theheater for operating an electrically operated component associated withthe mirror subassembly.

In a narrower form, the mirror assembly includes anelectrically-operated second component associated with the mirrorsubassembly, the second component including a third connector engagingthe second connector for electrifying the second component.

In still another narrower form, the rearview mirror assembly includes aprimary wire bundle extending from and configured to communicate powerto the heater and the second component, the primary wire bundleincluding a main connector engaging and electrically connected to thefirst connector, whereby the primary wire bundle is configured tocommunicate power to the first and second components in a manneroptimizing the positions of electrical connections necessary duringassembly to a vehicle.

In another aspect of the present invention, a rearview mirror assemblyfor a vehicle includes a mirror subassembly, and a heater positionedrelative to the mirror subassembly for heating the mirror subassembly.The heater is multi-layered and includes a polymeric layer oflight-transmitting material and includes another layer of opaquematerial with at least one aperture therein for letting light passthrough to the light-transmitting material. At least a portion of thelight-transmitting material covers the aperture and is configured todiffuse light passing through the portion. A light source directs lightat the portion, with the portion diffusing the light so that the lightpassing therethrough is uniformly distributed.

In another aspect of the present invention, a mirror includes anelectrochromic mirror subassembly including a panel-shaped carrier withflanges defining a pocket, and a printed circuit board positioned in thepocket. A releasable retainer releasably secures the printed circuitboard in the pocket.

In another aspect of the present invention, an exterior rearview mirrorincludes a mirror subassembly including a panel-shaped carrier, and aprinted circuit board attached to the panel-shaped carrier. The printedcircuit board includes light-generating devices positioned in a visiblelocation on the mirror subassembly to generate a visible turn signal andincludes at least a portion of a circuit for controlling thelight-generating devices. A retainer secures the printed circuit boardto the mirror subassembly characteristically without using a separatehousing for the printed circuit board.

In another aspect of the present invention, a mirror assembly includes ahousing, and an adjustment device attached to the housing. Theadjustment device includes an angularly adjustable mount. Anelectrochromic mirror subassembly includes front and rear glass elementsand an electrochromic layer adapted to provide controlled darkening ofreflected images, and further includes a panel-shaped carrier with afront surface shaped to uniformly support the rear glass element. Thepanel-shaped carrier includes a plurality of resilient retainersarranged in a circle. The resilient retainers extend rearwardly from thepanel-shaped carrier and engage the adjustable mount. The panel-shapedcarrier further includes a continuous hoop-shaped wall extending aroundand spaced radially from the plurality of resilient retainers. Thehoop-shaped wall extends from the rear surface and supports an areaaround and proximate a base of the plurality of resilient retainers sothat significant deflection of the panel-shaped carrier in the area ofthe resilient retainers is prevented even when the resilient retainersare stressed or have been stressed.

In still another aspect of the present invention, a mirror assemblyincludes a housing and an adjustment device attached to the housing. Theadjustment device includes an angularly adjustable mount. Anelectrochromic mirror subassembly includes front and rear glass elementsand an electrochromic layer adapted to provide controlled darkening ofreflected images, and further including a panel-shaped carrier with afront surface shaped to uniformly support the rear glass element. Thepanel-shaped carrier includes a plurality of resilient retainersarranged in a circle and extending rearwardly from the panel-shapedcarrier and engaging the adjustable mount. The retainers and adjustablemount are configured to positively engage for secure retention, but arealso configured to provide an insertion attachment force of less than 50pounds force (about 220 N) during assembly of the panel-shaped carrierto the adjustment device.

In yet another aspect of the present invention, an exterior mirrorassembly includes a housing with an arm adapting the housing forattachment to a vehicle in a position outside of the vehicle. Anadjustment device is attached to the housing and includes an angularlyadjustable mount. A mirror subassembly includes an electrochromic mirrorand a carrier for the electrochromic mirror. The carrier includes apanel-like surface supporting the electrochromic mirror and includesretainers engaging the adjustable mount. The carrier includes aplurality of apertures inboard of a perimeter of the carrier butoutboard of a perimeter of the electrochromic mirror, and further, themirror subassembly includes a bezel with a plurality of resilient hooksthat extend past the perimeter of the electrochromic mirror and into theplurality of apertures.

It is an object of the present invention to provide a vehicle mirrorthat is particularly suited for use as a vehicle mirror, where themirror includes numerous electrical components that must be powered andalso controlled, including such components and features aselectrochromic (EC) layers, heaters, turn signals, power packs forpowered angular adjustment of the mirror subassembly, sensors, readoutsand displays, and turn signals.

It is an object of the present invention to provide electrical connectorarrangements that facilitate connection of multiple connectors withminimized manual labor, minimized expensive components, minimized spaceproblems, and optimized locations.

It is an object of the present invention to integrate components toreduce redundant structure, to reduce overall thickness of the assembly,and to eliminate parts.

It is an object of the present invention to incorporate structure forthe housing of the turn signal device into other structure within themirror subassembly, as a way of reducing expense and assembly labor,saving space, saving material and reducing weight of the mirrorassembly.

It is an object of the present invention to releasably hold the circuitboard in the mirror subassembly, and hence provide a circuit board andelectrical component arrangement that is serviceable and repairable inthe field and also serviceable and repairable at the time of assemblingthe mirror assembly. In particular, it is an object to provide a mirrorassembly process that reduces scrap and cost of scrap by allowingserviceability as late in the mirror assembly process as possible, andby attaching non-removable components as late as possible in theassembly process.

It is an object of the present invention to provide an electrochromicmirror subassembly that utilizes glass elements having a relatively thinthickness dimension, such as a thickness of 1.6-mm or as low as 1.1-mmor lower, and to support these glass elements in a stress-free andforgiving manner that minimizes distortion. In particular, an object isto provide a carrier that supports the glass elements with minimalstress, yet that allows snap-assembly of a mirror subassembly to a powerpack, and that allows snap-assembly of a bezel to the mirrorsubassembly.

It is an object of the present invention to provide a minimizedinsertion force when attaching a mirror carrier to a power pack. Inparticular, it is desired that the insertion force not be unacceptablyhigh, such as below 50 pounds force of insertion, but that it be aconsistent force, that it be well-distributed and not be concentrated,that looseness and sloppiness be prevented, that the retention forces benon-distorting to the mirror glass elements, and that stresses resultingfrom environmental conditions such as temperature fluctuations notunacceptably bend glass elements and read through onto reflected images.

It is an object of the present invention to provide components that canbe molded with molding dies that are relatively low-cost to build andmaintain, such as by providing parts and components that can be moldedusing dies without movable pulls and without movable slides, which diepulls and slides are expensive to build into dies and to maintain.

It is an object of the present invention to construct a mirror assemblythat includes components that are easy to build and assemble, and thatcan be assembled reliably and efficiently with low cost.

It is an object of the present invention to provide a mirror assemblythat includes relatively few parts and pieces, especially small partsand pieces that must be manipulated and connected during assembly. It isdesired to include in the mirror assembly fewer loose parts and pieces,especially parts and pieces that can be mislocated and that can get inthe way and/or rattle and/or that must be accurately positioned duringassembly.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exterior mirror assembly embodyingthe present invention;

FIG. 2 is an enlarged schematic view of an angular adjustment mechanism(i.e. an electrical “power pack”) attached to an electrochromic mirrorsubassembly, with the flexible fingers of the mirror carrier being bentin a manner causing distortion of reflected images;

FIG. 2A is a cross section similar to FIG. 2, but showing a deformationof the glass elements in a mirror subassembly caused by bending of thecarrier, leading to distortion of a reflected image;

FIG. 3 is a rear view of the mirror subassembly, which shows the rearsurface of the carrier and also the wiring and electrical connectorarrangement;

FIGS. 4 and 5 are cross-sectional views taken along the lines IV-IV andV-V in FIG. 3;

FIG. 6 is an enlarged view of the circuit-board-holding pocket of thecarrier, which is an enlarged view of the right end of FIG. 4;

FIG. 7 is an enlarged cross-sectional view taken along the line VII-VIIin FIG. 3;

FIGS. 8 and 9 are cross-sectional views of the carrier and integrallymolded door retainer, similar to FIG. 7 but showing only the carrier(i.e. the mirror subassembly and circuit board are not shown), FIG. 8showing the door retainer in an open position and FIG. 9 showing thedoor retainer in a closed position (compare to FIG. 7);

FIG. 10 is a rear view of a modified mirror subassembly, including athree-into-one electrical connector arrangement;

FIG. 11 is a fragmentary view of the three-into-one electrical connectorof FIG. 10;

FIG. 12 is a rear view of a modified mirror subassembly, including anupstream two-into-one electrical connector and then a downstreamtwo-into-one electrical connector;

FIG. 13 is a rear view of another modified mirror subassembly, includinga two-into-one electrical connector and also a “piggyback” electricalconnector that plugs into or “piggybacks” onto a back of one of thefirst electrical connectors;

FIG. 14 is a fragmentary plan view of a heater including alight-blocking layer with apertures for letting light pass through, andincluding a light-passing layer treated to diffuse light passingtherethrough; and

FIG. 15 is a cross-sectional view taken along line XV-XV in FIG. 14.

DETAILED DESCRIPTION

The illustrated mirror assembly 20 (FIG. 1) includes a housing 21, anangular electrically-powered adjustment mechanism 22 (called a “powerpack” herein) (FIG. 2) supported in and attached to a wall 21′ in thehousing 21, and main wiring bundle 23 (FIG. 1) for powering andcontrolling the power pack 22 and the other components in the mirrorassembly 20. An electrochromic mirror subassembly 24 (FIG. 2) includes acarrier 36 snappingly attached to a multi-angularly-adjustable plate 48on the power pack 22 in a manner that minimizes stress on the glasselements of the mirror subassembly 24, as described below. The presentmirror assembly 20 is designed to prevent the problem illustrated inFIG. 2A, where resilient fingers on the carrier are stressed and havecaused a deformation on the glass elements of the mirror subassembly,resulting in unacceptable distortion of reflected images, as representedby non-parallel reflected light beams 19. (Compare with FIG. 2, wherethree light beams 17 representing an image are reflected as anundistorted image represented by parallel light beams 18.) The mirrorsubassembly 24 (FIG. 2) further includes a layer of electrochromicmaterial 25 and a heater 26, and also an integrally held turn signaldevice 27 (FIG. 3), each of which requires connection to a powering andcontrol device on the vehicle, as described below.

The components 25, 26, and 27 include individual connectors 25A, 26A,and 27A (FIG. 3) that each plug into a multi-prong, multi-receptaclemain connector 28 or secondary connector 28A on the bundle of wires 23.Alternatively, it is contemplated that a pair of the connectors couldpiggyback into each other (see FIG. 13), with the bottom connector beingplugged into the connector 28. Still another alternative is to use an“extension cord-type” arrangement where two two-prong connectors pluginto a single four-prong connector and then downstream the extensioncord's other connector plugs into the main connector (see FIG. 12). Thisarrangement can help provide flexibility for assembly, particularly whendifferent options are used for the mirror assembly, the signal device,and the EC mirror subassembly, but also can help with repair and withcontrol over the type, cost, and number of connectors. By thisarrangement, commercially available “standard” connectors can be usedinstead of higher-cost “specialty” connectors. Another alternativearrangement includes a heater that incorporates an internal wire withend connectors for communicating power to opposite sides of the heater(FIG. 12). Optionally, the heater can also include sections oflight-transmitting/diffusing material 34 (see FIGS. 14-15) for diffusinglight 35 passing from the turn signal device 27 through the diffusingmaterial 34.

The mirror subassembly 24 includes a panel-shaped carrier 36 (FIGS. 6-9)constructed to securely but releasably hold a circuit board 38 of theturn-signal device 27 and also constructed with a continuous hoop flange44 for rigidity. More specifically, the mirror subassembly 24 includesflanges 72 and 72A forming a pocket 37. A printed circuit board 38 withlight-generating devices 39 (such as LEDs) (FIG. 15) for generating apattern of light for the turn signal fits into the pocket 37. A doorretainer 40 (FIGS. 6-9) is integrally molded with the carrier 36, andincludes an integral hinge 41 and snap-attach retainers 42 thatreleasably secure the door retainer 40 in a closed position for securingthe printed circuit board 38 in the pocket 37. The carrier 36 alsoincludes a ring-shaped array of resilient fingers or retainers 43configured to snappingly engage a mounting plate on the power pack 22. Acontinuous hoop flange 44 (FIG. 3) of carrier 36 extends around thefingers 43 to prevent unacceptable distortion of the carrier 36 when thefingers 43 are attached to the power pack 22.

Exterior mirror housings such as housing 21 (FIG. 1) and also adjustablepower packs such as power pack 22 (FIG. 2) are generally well known inthe art, such that the present housing 21 and power pack 22 need not bedescribed in great detail for an understanding of the present inventionby a person skilled in the art of designing vehicle mirrors. It issufficient to describe the housing 21 as including a front opening 46 inwhich the mirror subassembly 24 is adjustably held for angularadjustment by the power pack 22. The power pack 22 includes DC motors 47for angularly adjusting an adjustable plate or mount 48 in orthogonalX-Y angular directions. The resilient fingers 43 on the carrier 36snappingly engage the adjustable plate 48 in a manner that facilitatesassembly via a low and consistent insertion force, yet positively retainthe carrier 36 to the power pack 22 with a consistently high retentionforce, as described below. The housing 21 further includes a rigidstructural arm 49 with attachment bolts 49′ shaped for secure attachmentto a vehicle body or door (not specifically shown).

The carrier 36 (FIGS. 3-4) includes a panel-like body section 50 shapedto fit inside the opening 46 of housing 21 and to support the mirrorsubassembly 24. The mirror subassembly 24 (FIG. 6) includes a frontglass element 51 having a thickness of about 1.6-mm or that is morepreferably about 1.1-mm or less, and a rear glass element 52 having athickness of about 2.2-mm to 1.1-mm or that is more preferably about1.6-mm. An electrochromic (EC) substance 53 is located between the glasselements 51 and 52. A reflector layer 54 is applied to a rear of therear glass element 52 (i.e. a fourth surface reflector) (as illustrated)or to a front of the rear glass element 52 (i.e. a third surfacereflector). It is contemplated that the EC substance can be a solutionphase material, a solid phase material, a gel material, or a hybridthereof or any other material that is darkenable in a controlled manner.An electrochromic mirror subassembly 24 of interest having low-thicknessglass elements is described in detail in U.S. Pat. No. 6,195,194, whichpatent is incorporated in its entirety herein by reference.

The heater 26 includes a foam layer 55 and a plastic layer 56 (e.g.Mylar or stiff plastic) with conductive tracings 57 thereon that formthe heater element. In the illustrated arrangement, the plastic layer 56is adhered to the reflector layer 54, and the foam layer 55 is adheredto the plastic layer 56 but not adhered to the carrier 36. Notably, theplastic and foam layers 56 and 55 could be reversed, and/or the adhesivelayer could be on the foam layer instead of the plastic layer. Theillustrated lack of adhesion between the plastic layer 56 and thecarrier 36 is a change from prior art that helps reduce stress on theglass elements 51 and 52. For example, such stress will occur due tonon-uniform thermal expansion, such as may occur during the day and/oroccur when the heater is first energized and is heating. This lack ofadhesion helps to reduce unacceptable distortion of the glass elements51 and 52 by permitting some slippage between the heater and the mirrorsubassembly 24.

The carrier 36 (FIG. 6) includes a perimeter section with a U-shapededge flange 58 having an aperture 59. A bezel 60 includes a J-shapedbody 61 that extends around a perimeter of the mirror subassembly 24,with a short end of the J-shaped body 61 engaging an area on the frontglass 51 just inside of a perimeter of the front glass 51, and with along end of the J-shaped body 61 extending past the glass elements 51and 52 into a groove formed by the U-shaped edge flange 58. The long endof the J-shaped body 61 is resilient and flexible, and includes aplurality of hooks 63 shaped to snap into the apertures 59. Due to theshape of the mating U-shaped edge flange 58 and the bezel 60, the bezel60 securely and reliably fits into the groove of the U-shaped edgeflange 58 and snaps into the apertures 59. In particular, the shape ofthe U-shaped edge flange 58 permits an assembler to flex the U-shapededge flange 58 forwardly, and permits an assembler to flex the short endof the J-shaped body 61 rearwardly, thus helping to assemble the bezel60 onto the edge flange 58 without “overflexing” and non-uniformlystressing and/or deforming the mirror subassembly 24 or the bezel 60 orthe carrier 36. Also, the arrangement helps prevent permanent“overflexing” or assembly-induced stress which would result inunacceptably/non-uniformly stressing or locally bending an edge of themirror subassembly 24. The section 64 of foam layer 55 along theperimeter of the heater 26 forms a compressed sandwich with the mirrorsubassembly 24, the bezel 60 and the carrier 36, with the foam section64 being compressed to about half its uncompressed thickness. Notably,the bezel 60 transmits compressive forces directly through the glasselements 51 and 52 of the mirror subassembly 24, thus substantiallyeliminating undesired torsional and bending stresses.

The carrier 36 also includes the hoop flange 44, which stabilizes andrigidifies the panel-like body section 50 of the carrier 36 around thepower-pack-attachment section (i.e. around the resilient snap-attachfingers 43). The hoop flange 44 is continuous, such that it inherentlyhas the strength and stress-distributing properties of a hoop. Further,the hoop flange 44 has a height of about 10-mm and a thickness at itstop edge of about 0.8-mm. This ratio of dimensions is an optimalcompromise permitting moldability (with minimal draft angle), whileproviding the strength and structure to provide support to resistresonant frequencies that can be problematic to an exterior mirror 20 inthe field when a car is in service. Reinforcement ribs 66 (FIG. 3)extend radially from the outer edge surface of the hoop flange 44 forstabilizing the hoop flange 44 on a rear of the panel-like body section50. The ribs 66 are located as needed. Some of the ribs 66 are extendedto provide support locations for electrical connectors, such as rib 66Adescribed below.

A hole 67 is located in the panel-like body section 50 in a middle areaof the attachment section (i.e. in a middle area of the ring of fingers43). The hole 67 prevents “oil canning”, which is a condition thatsometimes occurs on flat molded walls that are surrounded by rigidperimeter structure. “Oil canning” is the condition where flat materialflexes between “in” and “out” bowed conditions. The presence of the hole67 is consistent with the present structure, which emphasizes lettingthe glass element 51 and 52 of the mirror subassembly 24 float to anunstressed state, rather than attempting to continuously support theglass elements 51 and 52 in all locations across its rear surface. AU-shaped open area 69 is cut away from a root or base of the fingers 43to provide additional flexure of these fingers 43. Specifically, theU-shaped open area 69 is cut into the panel-like body section 50 toallow the fingers 43 to flex in a direction perpendicular to the fingers43. The U-shaped open area 69 causes the fingers 43 to flex open moreeasily, and lets them flex without disturbing and over-stressing thepanel-like body section 50. At the same time, an installer can pressdirectly on a back side of the fingers 43 to assure that the fingers 43are all securely snapped onto the plate mount 48 on the power pack 22.The fingers 43 (FIG. 6) include a hook-shaped end having an angledsurface 70 and they extend about 14-mm to 15-mm. The angled surface 70is polished and/or otherwise treated to reduce the friction ofinsertion. By polishing the angled surface 70, insertion forces of under50 pounds force (222 Newtons) have been achieved, which is surprisinglyand unexpectedly low for assembling a mirror subassembly 24 onto a powerpack 22. Many previous attempts have been made in the art to reduceinsertion forces, while maintaining a sure and consistently tight fit.The present arrangement of polished hook surfaces and flexible fingers43, in combination with the compressed foam of the heater 26, isbelieved to be novel and non-obvious to a person of ordinary skill inthis art, based on the effort that has gone into coming to the presentsolution to the problem.

The carrier 36 is a molded component having flanges 72 and 72A (FIG. 6)on all sides forming a well-defined boomerang-shaped pocket 37. (SeeFIG. 14.) A circuit board 38 (FIG. 6) is crescent-shaped orboomerang-shaped to fit mateably into the pocket 37, with edges of thecircuit board 38 being captured by the various flanges 72 and 72A. Aresilient angled biasing flange 73 (FIG. 7) on the carrier 36 is shapedto engage a side edge of the circuit board 38 to assure non-rattlingretention of the circuit board 38. The door-shaped retainer 40 is moldedas shown in FIG. 8, but is bendable about integral living hinge 41 intosnapping engagement with the integrally-molded retainers 42. Whenclosed, the door-shaped retainer 40 includes an edge opposite the livinghinge 41 that engages two hook-shaped retainers 42. However, it is to beunderstood that retainers 42 can be included to engage top and bottomedges of the retainer 40 as well. When closed, the door-shaped retainer40 engages the resilient biasing flange 73 in a manner that compressesthe retainer 40 against the blind surfaces on the hook retainers 42,thus assuring non-rattling securement of the door-shaped retainer 40.Notably, the living hinge 41 extends only about half a length of thedoor 40, such that wires 27A′ can be slid sideways into the hinge areaand routed into the pocket 37 without interference from the door 40 orhinge 41 or flanges 72 and 72A. The circuit board 38 includes thelight-generating devices 39 and circuits necessary for controlling thelight-generating devices 39 to generate an arrow-shaped turn signal. Itis noted that turn-signals have previously been put on external vehiclerearview mirrors (for example, see U.S. Pat. No. 6,166,848), but it isbelieved that no one has eliminated the separate turn signal housingshown in U.S. Pat. No. 6,166,848. The present apparatus incorporates thestructure for holding the turn signal circuit board and LEDs into thecarrier of the mirror subassembly itself. Notably, the illustratedcarrier 36 is designed so that it can be molded by dies that do not haveany die pulls, slides, cams, or moving components for making blindsurfaces. This lowers cost, reduces maintenance, reduces capitalinvestment, reduces scrap, and leads to an improved and more reliablemanufacturing process and better parts.

The present structure further incorporates the turn signal device 27into the mirror subassembly structure by using the plastic layer 56(FIG. 15) of Mylar in the heater 26 as a diffuser for thelight-generating devices 39 on the turn-signal device 27. Specifically,one or more apertures 74 are cut into the foam layer 55 of the heater26. The apertures 74 can be cut entirely through the foam if the lightgenerated by the turn signal device 27 is sufficiently dispersed toprovide a uniformly lit turn signal. However, the illustrated heater 26has a clear plastic layer 56 that extends across the pattern ofapertures 74. The plastic layer 56 is Mylar or similar clear material,and at least the area of sections 34 at the apertures 74 is roughened orotherwise treated to form a light-spreading/diffusing surface 34 overthe apertures 74. This surface causes the light 35 from LEDs 39 todiffuse into a more uniform distribution of light. Bars 39′ (FIG. 15) inthe windows on the EC material 53 and the relationship of componentscauses the emitted light 35′ to be visible. By this method, the need forseparate window/light diffusers on the light-generating devices 39 ofthe turn signal device 27 are eliminated. However, it is conceivablethat the pattern of apertures 74 can be cut completely through theheater 26, and that a separate light diffusing panel(s) could be usedinstead of the above-described integrated light diffuser that isintegrated into the heater 26.

The arrangement of connectors for interconnecting the electricallypowered and controlled components of the present mirror assembly 20 isvery important, since connectors take up space, particularly if notwell-arranged, since each additional connector adds cost, and since theyrequire manual labor to orient and snap together. Further, eachadditional connector is another opportunity for misconnection, and/orfor an electrical short or dead connection. Connectors and wires alsoadd weight and thickness to a mirror assembly. Four connectorarrangements are described below, each solving one or more of the aboveproblems and offering one or more of the above advantages.

Mirror assembly 20 (FIG. 3) includes the connector 26A, which comprisestwo protruding conductor leads 76 and 77 connected to the heating tracesin the heater 26. The main wiring bundle 23 includes a first connector28A for operably engaging leads 76 and 77. The main wiring bundle 23further includes a second connector 28 that snap engages into or that isincorporated into a holder 81. Holder 81 is snap-attached into anaperture in reinforcement rib 66A. The connectors 25A and 27A areconfigured to snap side-by-side into the holder 81 and electricallyconnect to different conductors in the second connector 28 on the mainwiring bundle 23. It is contemplated that the holder 81 can beincorporated into the second connector 28 or into one of the connectors25A and 27A, if desired. By plugging the two connectors 25A and 27Aside-by-side into the single connector 28, the total number ofconnectors is reduced. Also, the orientation and snap engagement of theconnectors 25A and 27A into connector 28 is easier since there is onelocation, and the first installed connector helps align and orient thesecond connector for installation. Also, the connectors 25A, 27A and 28are located close to connector 28A and leads 76 and 77, which alsofacilitates an efficient assembly, since an assembler does not need towaste time “searching for” the connectors.

The mirror assembly 20B (FIGS. 10-11) includes wires 83B and a heaterconnector 26B that replace the heater leads 76 and 77. The main wiringbundle 23B includes a connector 28B having six prong conductors therein.Main wiring bundle connector 28B snaps into or is incorporated into theholder 81B, which is retained by rib 66B. The EC connector 25B, theheater connector 26B, and the turn signal device connector 27B each plugside-by-side-by-side into the connector 28B of the main wiring bundle23B. As noted above, the side-by-side-by-side relationship of theconnectors creates an arrangement that is more efficient to assemble,since all connectors are close together and further since previouslyinstalled connectors guide the later-installed connectors. As arranged,the wires of the connectors 25B, 26B and 27B do not overlap, thusleading to a flatter and well-arranged wiring pattern. Preferably, theconnectors 25B, 26B, and 27B have different shapes so that they are notinterchangeable and cannot be mis-assembled.

The mirror assembly 20C (FIG. 12) includes conductors 83C that areintegrated into the heater 26C as part of the heater conductor tracings.The conductors 83C are used to connect the turn signal device 27C to themain wiring bundle 23C in an “extension cord” type arrangement. The turnsignal conductors 83C can extend along any convenient path from the leftside to the right side of the mirror subassembly 24C. The turn signalconductors 83C are shown in FIG. 12 as extending horizontally along anupper edge of the heater 26C for convenience so that they are easilyseen in the drawing and so that they do not interfere with the heatertracings of the heater 26C. It is contemplated that the turn signalconductors 83C could act as heating elements as well, but this is not apreferred mode. Instead, it is contemplated that they will define aseparate circuit extending between the turn signal device 27C and themain wires 23C.

The integrated turn signal conductors 83C can be electricallyinterconnected to the main connector 28C by various means. Theillustrated turn signal conductors 83C include protruding paired ends84C and 85C that are engaged by “L” connectors 86C and 87C,respectively. The turn signal device 27C is held to the carrier by doorretainer 40C, and includes wires 90C connected to connector 86C.Connector 87C engages the downstream protruding paired ends 85C for theturn signal device 27C and further engages the protruding paired ends26C′ extending from heating tracings 26C″. Wires 93C electricallyconnect the four conductors of the connector 87C to the second connector94C which in turn is connected to the main connector 28C. The connector25C connects the electrochromic material of the EC mirror to the mainconnector 28C. Wires 23C extend from the main connector 28C and areconnected to the vehicle electrical system.

Mirror 20D (FIG. 13) is similar to the mirror assembly 20B (FIG. 10),except the connector 27D from the turn signal device 27D′ connects intoa rear of the connector 25D in a “piggyback” style arrangement, and theconnector 25D (which is four prong) plugs into the main connector 28Dadjacent the “EC” connector 26D. More specifically, the connector 25Dhas two wires from the EC mirror subassembly hard wired into theconnector 25D, and further has four output prongs for connection to mainconnector 28D. Connector 26D attaches to the main connector 28D besideconnector 25D. Wires 23D extend from connector 28D for connection to thevehicle electrical system.

It is to be understood that variations and modifications can be made onthe aforementioned structure without departing from the concepts of thepresent invention, and further it is to be understood that such conceptsare intended to be covered by the following claims unless these claimsby their language expressly state otherwise.

1. A mirror assembly comprising: a mirror component including firstelectrical conductors operably connected to the mirror component; anelectrically-operated second component associated with the mirrorcomponent and that includes second electrical conductors operablyconnected to the electrically-operated second component; a firstconnector, said first and second electrical conductors operablyconnected to said first connector; and a primary wire bundle configuredto communicate power to the mirror component and to theelectrically-operated second component, the primary wire bundleincluding a main connector, the first connector engaging andelectrically connected to the main connector, whereby the primary wirebundle is configured to communicate power to the mirror component and tothe electrically-operated second component.
 2. The mirror assemblydefined in claim 1 and further comprising a second connector engagingand electrically connected to one of the main connector and the firstconnector.
 3. The mirror assembly defined in claim 1, wherein theelectrically-operated second component is a turn signal device adaptedto generate a turn signal.
 4. The mirror assembly defined in claim 1,wherein the first electrical conductors are electrically connected to asecond connector that is connected to the main connector through thefirst connector.
 5. The mirror assembly defined in claim 1, wherein theelectrically-operated second component is a heater for heating themirror component.
 6. The mirror assembly defined in claim 5, wherein themain connector has a least six terminals, two of the terminals beingconnected to a turn signal device, two of the terminals being connectedto the mirror component, and two of the terminals being connected to theheater.
 7. The mirror assembly defined in claim 1, including apanel-shaped carrier, and wherein the main connector and also the mirrorcomponent are attached to the carrier.
 8. The mirror assembly defined inclaim 1, including a housing with a laterally-extending structural armthat is adapted to support the mirror component on an exterior of avehicle body.
 9. The mirror assembly defined in claim 8, wherein themirror component is operably supported in the housing for angularadjustment.
 10. The mirror assembly defined in claim 9, including apower adjustment device releasably engaging the carrier and supportingthe mirror component in an opening in the housing.
 11. The mirrorassembly defined in claim 1, and further comprising a heater, whereinthe second component is a turn signal device, and wherein the firstconductors are internally integrated into the heater to provideelectrical power from the main connector across the heater to the turnsignal device.
 12. A mirror comprising: an mirror subassembly includinga panel-shaped carrier with flanges defining a pocket; a printed circuitboard positioned in the pocket; and a releasable retainer releasablyretaining the printed circuit board in the pocket.
 13. The mirrordefined in claim 12, including a housing with an arm extending from thehousing that is configured and adapted for attachment to an exterior ofa vehicle.
 14. The mirror defined in claim 12, including an electricallyoperated component, and wherein the circuit board is configured tooperate the electrically operated component.
 15. The mirror defined inclaim 14, and wherein the electrically operated component is a turnsignal device.
 16. The mirror defined in claim 12, wherein the retainerincludes a door for covering a recess in the carrier.
 17. The mirrordefined in claim 16, wherein the retainer is attached to the carrier bya living hinge.
 18. The mirror defined in claim 12, including resilientfingers integrally formed of material contiguous with the carrier andshaped to snappingly engage and secure the retainer.
 19. The mirrordefined in claim 16, wherein the retainer is integrally formed ofmaterial contiguous with the carrier and is attached to the carrier witha living hinge, and including integrally formed catches on the carrierfor snappingly engaging the door to retain the door in a closedposition.
 20. The mirror defined in claim 12, wherein the retainer isintegrally molded as part of the carrier.
 21. The mirror defined inclaim 12, wherein the carrier includes a living hinge connecting theretainer to the carrier and further is made without blind surfaces sothat the carrier can be molded with dies not having pulls, slides orother movable components for making blind surfaces.
 22. The mirrordefined in claim 21, including a first catch on a side of the retaineropposite the living hinge.
 23. The mirror defined in claim 22, furthercomprising a second catch on a side 90° from the first catch.
 24. Themirror defined in claim 12, wherein the circuit board includes lightsources for generating visible light.
 25. The mirror defined in claim24, wherein the light sources are positioned to form a pattern suitablefor use as a turn signal indicator.
 26. The mirror defined in claim 12,wherein the carrier includes a pressure foot in the pocket shaped toprevent looseness and rattling of the circuit board when the retainer isholding the circuit board.
 27. A mirror subassembly for use in arearview mirror assembly having a housing and a power pack attached tothe housing and including an angularly adjustable mount, said mirrorsubassembly comprising: a mirror subassembly including at least oneglass element, and further including a panel-shaped carrier with a frontsurface shaped to uniformly support the glass element, the panel-shapedcarrier including a plurality of resilient retainers arranged in acircle and extending rearwardly from the panel-shaped carrier andengaging the adjustable mount and further including a continuoushoop-shaped wall extending around and spaced radially from the pluralityof resilient retainers, the hoop-shaped wall extending from the rearsurface and supporting an area around and proximate a base of theplurality of resilient retainers.
 28. The mirror subassembly defined inclaim 27, wherein the hoop-shaped wall defines a constant radius. 29.The mirror subassembly defined in claim 27, wherein the hoop-shaped wallhas a constant height relative to a rear surface of the carrier.
 30. Themirror subassembly defined in claim 27, wherein the hoop-shaped wall hasconstant cross-sectional shape and thickness around the wall's entirelength.
 31. The mirror subassembly defined in claim 27, includingmarginal material defining an enlarged hole centered inside of theretainers, the marginal material forming a continuous ring inside of theretainers at a base of the retainers.
 32. The mirror subassembly definedin claim 27, wherein the retainers define flexible fingers with hookedends.
 33. The mirror subassembly defined in claim 27, wherein theretainers are uniformly spaced apart in a circumferential direction. 34.The mirror subassembly defined in claim 27, wherein the mirrorsubassembly includes a rear glass element that is 1.6-mm or less inthickness.
 35. The mirror subassembly defined in claim 27, wherein themirror subassembly includes a front glass element that is 1.6-mm or lessin thickness.
 36. The mirror subassembly defined in claim 27, whereinthe at least one glass element includes a front glass element and a rearglass element, at least one of which is 1.1-mm or less in thickness. 37.The mirror subassembly defined in claim 36, wherein the rear glasselement is adhered to the panel-shaped carrier.
 38. A mirror subassemblyfor use in a rearview mirror assembly having a housing and a power angleadjustment device attached to the housing and including an angularlyadjustable mount, said mirror subassembly comprising: a mirrorsubassembly including at least one glass element, and further includinga panel-shaped carrier with a front surface shaped to uniformly supportthe glass element, the panel-shaped carrier including a plurality ofresilient retainers arranged in a circle and extending rearwardly fromthe panel-shaped carrier and engaging the adjustable mount, theretainers and adjustable mount being configured to positively engage forsecure retention but also configured to provide an insertion attachmentforce of less than 50 pounds force (222 N) during assembly of thepanel-shaped carrier to the power pack.
 39. The mirror subassemblydefined in claim 38, including a resilient ring on the carrier inside ofthe retainers that abuts the adjustment device and is compressed betweenthe adjustment device and the carrier upon assembly.
 40. The mirrorsubassembly defined in claim 38, wherein the panel-shaped carrierincludes continuous rings of material radially inside and outside of theretainers to distribute the insertion attachment force uniformly over anextended area of the mirror subassembly.
 41. The mirror subassemblydefined in claim 38, wherein the retainers have inclined surfacesconfigured to provide low friction.
 42. The mirror subassembly definedin claim 41, wherein the inclined surfaces are smooth and formed on apolished die surface.
 43. The mirror subassembly defined in claim 38,including a foam positioned between the adjustable mount and thecarrier, and wherein the retainers grippingly engage the adjustablemount while compressing the foam.
 44. A mirror subassembly for use in arearview mirror assembly having a housing including an arm adapting thehousing for attachment to a vehicle in a position outside of the vehicleand a power pack attached to the housing and including an angularlyadjustable mount, said mirror subassembly comprising: a mirror; acarrier for the mirror, the carrier including a panel-like surfacesupporting the mirror and including retainers adapted for engaging theadjustable mount, the carrier including a plurality of apertures inboardof a perimeter of the carrier but outboard of a perimeter of the mirror;and a bezel with a plurality of resilient hooks that extend past theperimeter of the mirror and into the plurality of apertures.
 45. Amirror assembly comprising: a mirror component including firstelectrical conductors operably connected to the mirror component; anelectrically-operated second component associated with the mirrorcomponent and that includes second electrical conductors operablyconnected to the electrically-operated second component; and a commonconnector, said first and second electrical conductors operablyconnected to said common connector; wherein said common connector isconfigured for engaging and electrically connecting to a main connectorof a primary wire bundle, which supplies power to the mirror componentand to the electrically-operated second component.
 46. The mirrorassembly defined in claim 45, wherein the electrically-operated secondcomponent is a turn signal device adapted to generate a turn signal. 47.A mirror assembly comprising: a mirror component including firstelectrical conductors operably connected to the mirror component; anelectrically-operated second component associated with the mirrorcomponent and that includes a second electrical conductor operablyconnected to the electrically-operated second component; and anelectrically-operated third component associated with the mirrorcomponent and that includes second electrical conductors operablyconnected to the electrically-operated second component; and a commonconnector, wherein at least two of said first, second, and thirdelectrical conductors are operably connected to said common connector;wherein said common connector is configured for engaging andelectrically connecting to a main connector of a primary wire bundle,which supplies power to at least two of the mirror component, theelectrically-operated second component, and the electrically-operatedthird component.